Method and system for water soluble weak acidic resins as carbon precursors for silicon-dominant anodes

Abstract

Systems and methods for water soluble weak acidic resins as carbon precursors for silicon-dominant anodes may include an electrode coating layer on a current collector, where the electrode coating layer is formed from silicon and a primary resin carbon precursor; wherein the primary resin carbon precursor comprises a water-soluble acidic polyamide imide functionalized with acidic groups and one or more polymeric stabilizing additives. The electrode coating layer may also include a base and/or a surfactant. The electrode coating layer may be more than 70% silicon.

The invention claimed is: 
     
       1. A method of forming an electrode, the method comprising:
 fabricating a battery electrode comprising an electrode coating layer on a current collector, the electrode coating layer formed from silicon and a primary resin carbon precursor; wherein said primary resin carbon precursor comprises a water-soluble acidic polyamide imide functionalized with acidic groups and one or more polymeric stabilizing additives; and wherein the electrode coating layer also comprises one or more bases; and 
 wherein the one or more polymeric stabilizing additives comprises one or more of polyacrylic acid (PAA); poly (maleic acid, methyl methacrylate/methacrylic acid, butadiene/maleic acid); water soluble PAA: polyimide; ammonium lignosulfonate; kraft lignin; dextran; pullulan (polysaccharide polymer); phenolic resins; formaldehyde based resins; melamine-formaldehyde based resins; silane based resins; polyurethane; acrylic emulsions; chitosan; polymethyl methacrylate; poly(methacrylic acid); poly(vinyl acetate)/poly(vinyl alcohol) complexes: water-based acrylic and stryrene-acrylic emulsion polymers; carboxylated styrene-butadiene binders; acrylic resin; rotaxane; poly(acrylic acid); cellulose; starch; polysacharides; glycogen; carbohydrates; and polymers with backbones comprising sucrose, glucose, sucralose, xylitol, sorbitol, sucralose, glucosidases, galactose, and maltose. 
 
     
     
       2. The method according to  claim 1 , wherein the electrode coating layer further comprises one or more surfactants. 
     
     
       3. The method according to  claim 1 , wherein the one or more bases comprises Triethanolamine, Triethylamine, N-Methyldiethanolamine, Butyldiethanolamine, Diethylamine, Ethylamine, Tetrabutylammonium hydroxide, Tetramethylammonium hydroxide, Tetramethylammonium hydroxide, Triisopropanolamine, Trolamine, Amino-2-propanol, Triisobutylamine, N-Isopropyl-N-methyl-tert-butylamine, 2-Amino-2-methyl-1-propanol, 1-Amino-2-butanol, 2-Amino-1-butanol, Diethanolamine, Ethanolamine, 2-Dimethylaminoethanol, N-Phenyldiethanolamine, 2-(Dibutylamino)ethanol, 2-(Butylamino)ethanol, N-tert-Butyldiethanolamine, N-Ethyldiethanolamine, Avridine, and 2-(Diisopropylamino)ethanol. 
     
     
       4. The method according to  claim 1 , wherein the current collector comprises a metal foil. 
     
     
       5. The method according to  claim 1 , wherein the metal current collector comprises one or more of a copper, tungsten, stainless steel, and nickel foil in electrical contact with the electrode coating layer. 
     
     
       6. The method according to  claim 1 , wherein the electrode coating layer comprises more than 70% silicon. 
     
     
       7. The method according to  claim 1 , wherein the battery electrode is in a lithium ion battery. 
     
     
       8. A battery electrode, the electrode comprising:
 an electrode coating layer on a current collector, the electrode coating layer formed from silicon and a primary resin carbon precursor; wherein said primary resin carbon precursor comprises a water-soluble acidic polyamide imide functionalized with acidic groups and one or more polymeric stabilizing additives; and wherein the electrode coating layer also comprises one or more bases; and 
 wherein the one or more polymeric stabilizing additives comprises one or more of polyacrylic acid (PAA); poly (maleic acid, methyl methacrylate/methacrylic acid, butadiene/maleic acid); water soluble PAA; polyimide; ammonium lignosulfonate; kraft lignin; dextran; pullulan (polysaccharide polymer); phenolic resins; formaldehyde based resins; melamine-formaldehyde based resins: silane based resins: polyurethane; acrylic emulsions; chitosan; polymethyl methacrylate; poly(methacrylic acid); poly(vinyl acetate)/poly(vinyl alcohol) complexes; water-based acrylic and stryrene-acrylic emulsion polymers; carboxylated styrene-butadiene binders; acrylic resin; rotaxane; poly(acrylic acid): cellulose; starch; polysacharides; glycogen; carbohydrates; and polymers with backbones comprising sucrose, glucose, sucralose, xylitol, sorbitol, sucralose, glucosidases, galactose, and maltose. 
 
     
     
       9. The electrode according to  claim 8 , wherein the electrode coating layer further comprises one or more surfactants. 
     
     
       10. The electrode according to  claim 8 , wherein the one or more bases comprises Triethanolamine, Triethylamine, N-Methyldiethanolamine, Butyldiethanolamine, Diethylamine, Ethylamine, Tetrabutylammonium hydroxide, Tetramethylammonium hydroxide, Tetramethylammonium hydroxide, Triisopropanolamine, Trolamine, Amino-2-propanol, Triisobutylamine, N-Isopropyl-N-methyl-tert-butylamine, 2-Amino-2-methyl-1-propanol, 1-Amino-2-butanol, 2-Amino-1-butanol, Diethanolamine, Ethanolamine, 2-Dimethylaminoethanol, N-Phenyldiethanolamine, 2-(Dibutylamino)ethanol, 2-(Butylamino)ethanol, N-tert-Butyldiethanolamine, N-Ethyldiethanolamine, Avridine, and 2-(Diisopropylamino)ethanol. 
     
     
       11. The electrode according to  claim 8 , wherein the current collector comprises a metal foil. 
     
     
       12. The electrode according to  claim 8 , wherein the metal current collector comprises one or more of a copper, tungsten, stainless steel, and nickel foil in electrical contact with the electrode coating layer. 
     
     
       13. The electrode according to  claim 8 , wherein the electrode coating layer comprises more than 70% silicon. 
     
     
       14. The electrode according to  claim 8 , wherein the electrode is in electrical and physical contact with an electrolyte. 
     
     
       15. The electrode according to  claim 8 , wherein the battery electrode is in a lithium ion battery. 
     
     
       16. A battery, the battery comprising:
 a cathode, a separator, an electrolyte, and an anode, the anode comprising. an electrode coating layer on a current collector, the electrode coating layer formed from silicon and a primary resin carbon precursor; wherein said primary resin carbon precursor comprises a water-soluble acidic polyamide imide functionalized with acidic groups and one or more polymeric stabilizing additives; and wherein the electrode coating layer also comprises one or more bases; and 
 wherein the one or more polymeric stabilizing additives comprises one or more of polyacrylic acid (PAA); poly (maleic acid, methyl methacrylate/methacrylic acid, butadiene/maleic acid); water soluble PAA; polyimide; ammonium lignosulfonate; kraft lignin; dextran; pullulan (polysaccharide polymer); phenolic resins; formaldehyde based resins; melamine-formaldehyde based resins; silane based resins; polyurethane; acrylic emulsions; chitosan; polymethyl methacrylate; poly(methacrylic acid); poly(vinyl acetate)/poly(vinyl alcohol) complexes; water-based acrylic and stryrene-acrylic emulsion polymers; carboxylated styrene-butadiene binders; acrylic resin; rotaxane; poly(acrylic acid); cellulose; starch; polysacharides; glycogen; carbohydrates; and polymers with backbones comprising sucrose, glucose, sucralose, xylitol, sorbitol, sucralose, glucosidases, galactose, and maltose.